Pile fabric and method for manufacturing same

ABSTRACT

A pile fabric includes ground yarns constituting a ground structure; pile fibers that are tangled with the ground yarns, the pile fibers including portions standing on a front surface side of the ground structure; and an organically-modified silicone-based softener adhered to the pile fibers located on a back surface side of the pile fabric. The pile fibers include at least one selected from the group consisting of acrylic fibers and modacrylic fibers, and have a softening point lower than a softening point of the ground yarns. The portions standing on the front surface side of the ground structure are not fused to each other, and on a back surface side of the ground structure, at least part of the pile fibers located outside of the ground yarns are fused to each other.

TECHNICAL FIELD

One or more embodiments of the present invention relate to a pile fabricwith high softness that prevents pile fibers from falling off, and amethod for producing the same.

BACKGROUND

Pile fabrics have been known as fabrics that are made to look like furs,and called imitation furs, fake furs, boas, etc. The pile fabrics areconstituted by pile knitting or pile weave. Knitted piles are generallyformed using seal-fraise knitting machines or sliver knitting machines(circular knitting machines), and in either cases pile fibers are cut.In the case of using double Russell machines (warp knitting machines),knitted piles are formed by making a double ground structure whiletangling the double ground structure with binder yarns, and cutting themiddle of the binder yarns. In weaving, velvet looms or moquette loomsare used to tangle a pair of upper and lower ground structures andbetween the ground structures with binder yarns, and cut the middle ofthe upper and lower base fabrics with a knife to obtain two wovenfabrics simultaneously. However, such woven and knitted fabrics,particularly knitted fabrics such as high pile fabrics, have a largeamount of falling-off of fibers.

In order to prevent the falling-off of fibers of pile fabrics, therehave been a proposal of mixing low-melting fibers into pile fibers(Patent Document 1), and a proposal of mixing low-melting fibers intoground yarns constituting a ground structure (Patent Documents 2-3).However, in these proposals, since the whole fabric is heated at atemperature equal to or higher than the melting point of the low-meltingfibers, the entire ground structure or pile fibers are also fused,resulting in a coarse texture.

Patent Document 4 proposes a pile fabric made from specific fibers,which can prevent pile fibers from falling off without impairing thetexture of the piloerection surface by fusing only specific parts of thepile fibers on the back surface side of the pile fabric.

PRIOR ART DOCUMENTS Patent Documents

-   Patent Document 1: JP H06(1994)-081248 A-   Patent Document 2: JP 2000-314048 A-   Patent Document 3: JP H07(1995)-048765 A-   Patent Document 4: WO 2011/055455

However, in the pile fabric of Patent Document 4, the fusion of the pilefibers on the back surface side of the pile fabric sometimes hardens theback surface of the pile fabric, which accordingly hardens the pilefabric.

One or more embodiments of the present invention provide a pile fabrichaving improved softness while preventing pile fibers from falling offin a pile fabric in which at least parts of pile fibers located on theback surface side of the pile fabric are fused, and a method forproducing the same.

SUMMARY

One or more embodiments of the present invention relate to a pile fabricthat includes: a ground structure; and pile fibers that are tangled withground yarns constituting the ground structure and that stand on a frontsurface side of the ground structure. The pile fibers include at leastone selected from the group consisting of acrylic fibers and modacrylicfibers and have a lower softening point than fibers constituting theground structure. Among the pile fibers tangled with the ground yarnsconstituting the ground structure, the pile fibers standing on the frontsurface side of the ground structure are not fused, whereas at leastparts of the pile fibers located on a back surface side of the groundstructure outside of the ground yarns constituting the ground structureare fused. 0.4 parts by weight or more of an organically-modifiedsilicone-based softener is adhered with respect to 100 parts by weightof the pile fibers located on a back surface side of the pile fabric.The organically-modified silicone-based softener is at least oneselected from the group consisting of amino-modified silicone-basedsofteners, epoxy-modified silicone-based softeners, andcarboxyl-modified silicone-based softeners.

One or more embodiments of the present invention further relate to amethod for producing the pile fabric described above. The pile fabricincludes: a ground structure; and pile fibers that are tangled withground yarns constituting the ground structure and that stand on a frontsurface side of the ground structure. The pile fibers include at leastone selected from the group consisting of acrylic fibers and modacrylicfibers and have a lower softening point than fibers constituting theground structure. 0.4 parts by weight or more of an organically-modifiedsilicone-based softener is adhered with respect to 100 parts by weightof the pile fibers located on a back surface side of the pile fabric.The organically-modified silicone-based softener is at least oneselected from the group consisting of amino-modified silicone-basedsofteners, epoxy-modified silicone-based softeners, andcarboxyl-modified silicone-based softeners. The back surface side of thepile fabric is subjected to heat sensitive sealing at a temperatureequal to or higher than the softening point of the pile fibers and lowerthan the softening point of the fibers constituting the groundstructure, so that among the pile fibers tangled with the ground yarnsconstituting the ground structure, the pile fibers standing on the frontsurface side of the ground structure are not fused, whereas at leastparts of the pile fibers located on a back surface side of the groundstructure outside of the ground yarns constituting the ground structureare fused.

The organically-modified silicone-based softener may be anamino-modified silicone-based softener. The pile fibers may bemodacrylic fibers. The ground yarns may be polyester fiber yarns. 0.4 to2.5 parts by weight of the organically-modified silicone-based softenermay be adhered with respect to 100 parts by weight of the pile fiberslocated on the back surface side of the pile fabric.

One or more embodiments of the present invention can provide a pilefabric having improved softness while preventing the falling-off of pilefibers (pile fiber loss). Moreover, the production method of the pilefabric according to one or more embodiments of the present inventionenables easy production of pile fabrics having improved softness whilepreventing the pile fiber loss.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic view for explaining a positional relationshipbetween ground yarns and pile fibers tangled with the ground yarns inhigh pile fabrics in one or more embodiments of the pile fabric of thepresent invention.

FIG. 2 illustrates a production process showing an exemplary method forproducing the pile fabric according to one or more embodiments of thepresent invention.

FIG. 3 is a schematic view for explaining a method for measuring theamount of the fiber loss of pile fabrics in one or more embodiments ofthe present invention.

FIGS. 4A and 4B are schematic cross-sectional views for explaining amethod for evaluating the softness of pile fabrics in one or moreembodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

The present inventors repeatedly examined ways to improve the softnessof pile fabrics while preventing the pile fiber loss in pile fabricsthat include as pile fibers at least one selected from the groupconsisting of acrylic fibers and modacrylic fibers, wherein at leastparts of the pile fibers among the pile fibers located on the backsurface side of the pile fabric outside of the ground yarns are fused.As a result, the inventors found that it is possible to improve thesoftness of pile fabrics while preventing the pile fiber loss byadhering 0.4 parts by weight or more of an organically-modifiedsilicone-based softener with respect to 100 parts by weight of the pilefibers on the back surface side of the pile fabric, theorganically-modified silicone-based softener being at least one selectedfrom the group consisting of amino-modified silicone-based softeners,epoxy-modified silicone-based softeners, and carboxyl-modifiedsilicone-based softeners. Softeners (also called soft finishing agents)generally impart softness and smoothness of fiber surfaces. In thepresent disclosure, it was surprisingly found that it is possible toimprove the softness of pile fabrics while preventing the pile fiberloss by adhering a given amount of a specific softener to the pilefibers located on the back surface side of the pile fabrics.

A pile fabric according to one or more embodiments of the presentinvention is a pile fabric including: a ground structure; and pilefibers that are tangled with ground yarns constituting the groundstructure and that stand on the front surface side of the groundstructure. There is no particular limitation on the pile fabric, andexamples thereof include high pile fabrics, boa fabrics, and tuftedcarpets. The pile fabric according to one or more embodiments of thepresent invention is particularly suitable for high pile fabrics, whichoften cause the pile fiber loss. The high pile fabrics are notparticularly limited, but they may be, e.g., fabrics with a pile fiberlength of 15 to 100 mm at piloerection portion.

The high pile fabrics are pile knitted fabrics, and the ground structureis stockinette. Specifically, the high pile fabrics include; astockinette ground structure; and pile fibers that are tangled withground yarns constituting the ground structure while standing on a frontsurface side of the ground structure. Since the ground structure of thehigh pile fabrics is stockinette, the structure can have excellentstretchability. Stockinette is generally a fabric formed by making aloop with one or more yarns, hooking the loop to make a next new loop,and continuously making loops in a planar shape. The weft stockinettestitch, in which knitting proceeds in the weft direction, forms a planarfabric by making loops with yarns reciprocatingly from side to side, orforms a tubular fabric by making loops spirally. The warp stockinettestitch forms a fabric by making loops with a plurality of orderlyarranged warp yarns while intermeshing the yarns with adjacent left andright warp yarns via loops. Examples of the weft stockinette stitchinclude plain stitch, rib stitch, and purl stitch. Examples of the warpstockinette stitch include Denbigh stitch, cord stitch, atlas stitch,and chain stitch. The stitch of the ground structure of the high pilefabrics may be weft stockinette stitch from the viewpoint ofmarketability and productivity.

In one or more embodiments of the present invention, the arrangement ofthe pile fibers with respect to the stockinette ground structure may be,e.g., an arrangement in which the pile fibers are tangled with all ofthe loops of the ground yarns constituting the stockinette groundstructure, or an arrangement in which the pile fibers are not tangledwith some of the loops of the ground yarns constituting the stockinetteground structure in the wale direction and/or course direction.

Any fibers having a higher softening point than the pile fibers can beused as the fibers constituting the ground structure, i.e., the fibersconstituting the ground yarns. Examples of the fibers constituting theground structure include polyester fibers and cellulose-based fibers.The polyester fibers may be, e.g., synthetic fibers obtained by spinninga resin composition containing a polyester resin such as polyethyleneterephthalate. The cellulose-based fibers may be, e.g., cotton. Theground yarns may be polyester fiber yarns from the viewpoint ofpreventing the pile fiber loss while improving the softness of pilefabrics more effectively.

The pile fibers have a lower softening point than the fibersconstituting the ground structure. Among the pile fibers tangled withthe ground yarns, part or all of the pile fibers located on the backsurface side of the ground structure outside of the ground yarns arefused, whereas the pile fibers standing on the front surface side of theground structure are not fused. Although there is no particularlimitation on the means for fusing the pile fibers, the pile fabric maybe subjected to heat sensitive sealing from the back surface side of thepile fabric at a temperature equal to or higher than the softening pointof the pile fibers and lower than the softening point of the fibersconstituting the ground structure.

The pile fibers include acrylic fibers and/or modacrylic fibers, andthus a pile fabric with an excellent texture can be obtained. If thepile fibers are thermoplastic fibers, and a polishing process isperformed at a temperature equal to or higher than the melting point orsoftening point of the thermoplastic fibers, generally, the pile fiberson the front surface side of the pile fabric burn or melt, and a pilefabric with a favorable appearance and texture cannot be obtained. Ifthe polishing process is performed at a temperature equal to or lowerthan the glass transition point of the thermoplastic fibers, crimps ofthe pile fibers on the front surface side of the pile fabric are notstraightened, and a pile fabric with a favorable appearance and texturecannot be obtained. On the other hand, crimps of acrylic fibers andmodacrylic fibers can be straightened at temperatures lower than themelting point. The acrylic fibers and modacrylic fibers have a glasstransition point of about 100° C. and a softening point of about 150 to230° C. If the pile fibers are acrylic fibers and/or modacrylic fibers,the polishing process can be performed at temperatures equal to orhigher than the glass transition point and equal to or lower than thesoftening points, e.g., at temperatures of 100 to 150° C. Moreover,there is a tendency that crimps of the acrylic fibers and modacrylicfibers are straightened more easily than crimps of fibers of othermaterials, and thus a pile fabric with a favorable appearance andtexture can be obtained.

The pile fibers may contain synthetic fibers that are produced byspinning a resin composition containing a polyester resin (e.g.,polyethylene terephthalate, polytrimethylene terephthalate), or otherfibers.

The pile fibers are not particularly limited as long as the softeningpoint is lower than the softening point of the fibers constituting theground yarns. A difference between the softening point of the fibersconstituting the ground yarns and the softening point of the pile fibersmay be 10° C. or more, 20° C. or more, or 30° C. or more. By setting thedifference to be 10° C. or more, it becomes easier to subject only partor all of the pile fibers located on the back surface side of the pilefabric outside of the ground yarns to heat sensitive sealing for fusion,and not to subject the pile fibers standing on the front surface side ofthe ground structure to heat sensitive sealing.

The pile fibers may be fibers that are all softened at a predeterminedtemperature, or mixed fibers including fibers softened at differenttemperatures. When the pile fibers are mixed fibers including fiberssoftened at different temperatures, fibers softened at a relatively lowtemperature may be mixed in an amount of 20% by weight (wt %) or more,or 50 wt % or more, and the fibers softened at a relatively lowtemperature may be subjected to heat sensitive sealing.

In one or more embodiments of the present invention, the softening pointmeans a softening temperature before fusion or decomposition. Forexample, the softening point of the acrylic fibers is 190 to 232° C.,and the softening point of the modacrylic fibers is 150 to 220° C.(“Encyclopaedia Chimica”, page 727-729, published by Kyoritsu ShuppanCo., Ltd., Jun. 1, 1993; hereinafter, referred to as “literaturevalue”).

In one or more embodiments of the present invention, the acrylic fibersare fibers made up of a polymer obtained by polymerizing a compositioncontaining acrylonitrile in an amount of 85 wt % or more and othercopolymerizable monomers in an amount of 15 wt % or less. The modacrylicfibers are fibers made up of a polymer obtained by polymerizing acomposition containing acrylonitrile in an amount of 35 wt % or more andless than 85 wt % and other copolymerizable monomers in an amount ofmore than 15 wt % and 65 wt % or less.

In one or more embodiments of the present invention, there is noparticular limitation on the copolymerizable monomers as long as theycan be copolymerized with acrylonitrile. Examples of the copolymerizablemonomers include: vinyl halides represented by vinyl chloride and vinylbromide; vinylidene halides represented by vinylidene chloride andvinylidene bromide; sulfonic acid-containing monomers represented byallylsulfonic acid, methallylsulfonic acid, styrenesulfonic acid,isoprenesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, andtheir metal salts and amine salts; lower alkyl esters of acrylic acidand methacrylic acid, N-alkyl substituted aminoalkyl esters, N,N-alkylsubstituted aminoalkyl esters and glycidyl esters; acrylamide,methacrylamide, and their N-alkyl substituted products and N,N-alkylsubstituted products; anionic vinyl monomers such as carboxylgroup-containing vinyl monomers represented by acrylic acid, methacrylicacid and itaconic acid and their sodium, potassium or ammonium salts;cationic vinyl monomers represented by quaternary aminoalkyl esters ofacrylic acid and quaternary aminoalkyl esters of methacrylic acid; vinylgroup-containing lower alkyl ethers; vinyl group-containing lowercarboxylic acid esters represented by vinyl acetate; and styrene. Thesemonomers may be used alone or in a combination of two or more kinds.

As the copolymerizable monomers, one or more kinds of monomers selectedfrom the group consisting of vinyl halides, vinylidene halides, andmetal salts of sulfonic acid-containing monomers may be used. One ormore kinds of monomers selected from the group consisting of vinylchloride, vinylidene chloride, and sodium styrenesulfonate may be used.

The pile fibers may be modacrylic fibers, such as modacrylic fibersobtained by polymerizing a composition containing acrylonitrile in anamount of 35 wt % or more and less than 85 wt %, and vinyl chlorideand/or vinylidene chloride and other copolymerizable monomers in a totalamount of more than 15 wt % and 65 wt % or less.

In one or more embodiments of the present invention, there is noparticular limitation on the combination of the fibers constituting theground yarns and the pile fibers, as long as the above conditions aresatisfied. The following describes specific examples of the combination.

When the fibers constituting the ground yarns are fibers of, e.g.,polyethylene terephthalate (PET, softening point: about 258° C.), thepile fibers may be modacrylic fibers or mixed fibers of modacrylicfibers and acrylic fibers. The following are favorably used as themodacrylic fibers.

(1) Vinyl chloride-acrylonitrile fiber (e.g., trade name “Kanekalon”manufactured by Kaneka Corporation, softening point: 150 to 220° C.,literature value)

(2) Vinylidene chloride-acrylonitrile fiber (softening point: 150 to220° C., literature value)

When the fibers constituting the ground yarns are fibers of, e.g.,cotton (tree cotton, no softening point), the pile fibers may be acrylicfibers. An example of the acrylic fibers is “Exlan K691” (trade name)manufactured by Exlan Co., Ltd., (softening point: 190 to 232° C.,literature value).

An organically-modified silicone-based softener that is at least oneselected from the group consisting of amino-modified silicone-basedsofteners, epoxy-modified silicone-based softeners, andcarboxyl-modified silicone-based softeners, is adhered to at least thepile fibers located on the back surface side of the pile fabric. Theorganically-modified silicone-based softener such as an amino-modifiedsilicone-based softener may or may not be adhered to the pile fibers onthe front surface side of the pile fabric. The adhesion amount of theorganically-modified silicone-based softener such as an amino-modifiedsilicone-based softener to the pile fibers located on the back surfaceside of the pile fabric may be larger than the adhesion amount of theorganically-modified silicone-based softener such as an amino-modifiedsilicone-based softener to the pile fibers located on the front surfaceside of the pile fabric, from the viewpoint of preventing the fiber losswhile improving the softness of the pile fabric more effectively.Hereinafter, the “organically-modified silicone-based softener” refersto at least one selected from the group consisting of amino-modifiedsilicone-based softeners, epoxy-modified silicone-based softeners, andcarboxyl-modified silicone-based softeners unless otherwise specified.There is no particular limitation on the amino-modified silicone-basedsofteners as long as they are softeners containing as a main component apolysiloxane containing an amino functional group. There is noparticular limitation on the epoxy-modified silicone-based softeners aslong as they are softeners containing as a main component a polysiloxanecontaining an epoxy functional group. There is no particular limitationon the carboxyl-modified silicone-based softeners as long as they aresofteners containing as a main component a polysiloxane containing acarboxyl functional group. Here, the “main component” refers to acomponent contained in an amount of, for example, 40 wt % or more, 50 wt% or more, 60 wt % or more, or 70 wt % or more, with respect to thetotal weight of the solid content in the softener. Softeners other thanthe organically-modified silicone-based softener may be adhered to thepile fibers on the back surface side and/or the front surface side ofthe pile fabric.

The organically-modified silicone-based softener may be anamino-modified silicone-based softener from the viewpoint of preventingthe pile fiber loss while improving the softness of the pile fabric moreeffectively. The amino-modified silicone-based softener is notparticularly limited, and may be a solution in which an amino-modifiedpolysiloxane, which is commonly used as a soft finishing agent forfibers, is dispersed by a method such as emulsification. In theamino-modified polysiloxane to be used herein, amino functional groupsmay be attached to one or both terminals of the polysiloxane (mainchain), or attached to the side chains, or attached to the terminals andthe side chains. Though there is no particular limitation on thestructure of the amino functional groups, the examples include amonoamine type, a diamine type, a triamine type, and a polyamine type.Though there is no particular limitation on the amino-modifiedsilicone-based softener, it is possible to use marketed softeners suchas “Matsumoto Silicone Softener N-20” manufactured by MatsumotoYushi-Seiyaku Co., Ltd., “POLON-MF-14” manufactured by Shin-EtsuChemical Co., Ltd., and “TSF4702” manufactured by Momentive PerformanceMaterials Inc.

In the pile fabric in which at least parts of the pile fibers located onthe back surface side of the pile fabric outside of the ground yarns arefused, generally, the softness of the back surface of the pile fabric isenhanced by adhering a backing resin such as an acrylic ester-basedresin used for back coating of pile fabrics, to the back surface of thepile fabric. Meanwhile, in one or more embodiments of the presentinvention, the softness of the pile fabric is enhanced by adhering theorganically-modified silicone-based softener such as an amino-modifiedsilicone-based softener to the pile fibers located on the back surfaceside of the pile fabric without adhering a backing resin to the backsurface of the pile fabric. Moreover, the touch (softness, lowfrictional properties) of the back surface of the pile fabric improvesby adhering the organically-modified silicone-based softener to the pilefibers located on the back surface side of the pile fabric withoutadhering a backing resin to the back surface of the pile fabric.

There is no particular limitation on the adhesion amount of theorganically-modified silicone-based softener as long as 0.4 parts byweight or more of the organically-modified silicone-based softener isadhered with respect to 100 parts by weight of the pile fibers on theback surface side of the pile fabric. However, the adhesion amount ofthe organically-modified silicone-based softener may be 0.4 to 2.5 partsby weight, 0.4 to 2.0 parts by weight, or 0.4 to 1.5 parts by weight,with respect to 100 parts by weight of the pile fibers located on theback surface side of the pile fabric. Within the above range of theadhesion amount of the organically-modified silicone-based softener, itis possible to prevent the pile fiber loss while improving the softnessof the pile fabric more effectively. The adhesion amount of theorganically-modified silicone-based softener such as an amino-modifiedsilicone-based softener in the pile fibers can be determined by, e.g.,X-ray fluorescence analysis. For example, the adhesion amount of theamino-modified silicone-based softener can be determined by quantifyingthe Si element in accordance with X-ray fluorescence analysis using awavelength dispersion type X-ray fluorescence analyzer, and creating thecalibration curve. Specifically, with use of an X-ray fluorescencespectrometer RIX 3100 (manufactured by Rigaku Corporation), the Sielement is analyzed under the following conditions: Rh tube (tubecurrent: 50 mA−tube voltage: 50 kV), measurement diameter: 30 mmϕ,analyzing crystal:pentaerythritol (PET), and 2θ angle: 106 to 112°, andfirst, a calibration curve is created using a sample whoseamino-modified silicone-based softener content is known. Next, the Sielement of a measurement sample (thickness: 3 mm, diameter: 30 mm) isanalyzed which is obtained by molding fibers to be measured (e.g.,fibers on the back surface side of the pile fabric other than the groundyarns (i.e., pile files)) with pressure using a press (tablet moldingmachine). The adhesion amount of the amino-modified silicone-basedsoftener can be calculated by substituting the obtained Si detectioncount into a calibration curve equation.

It is possible to use a backing resin. Any backing resin that iscommonly used for back coating of pile fabrics can be used as thebacking resin. Examples of the backing resin include acrylic ester-basedresins and polyurethane-based resins. In the case of using the backingresin, the back surface of the pile fabric may be impregnated with thebacking resin prior to a heat sensitive sealing step in the productionmethod of the pile fabric to be described later. The impregnation of thebacking resin can be performed using, e.g., latexes, emulsions, anddispersions of acrylic ester-based resins and polyurethane-based resins.The backing resin may be used alone or in a combination of two or morekinds.

Hereinafter, the pile fabric according to one or more embodiments of thepresent invention will be described with reference to the drawings. FIG.1 is a schematic view for explaining a positional relationship betweenground yarns and pile fibers tangled with the ground yarns in a highpile fabric in one or more embodiments of the pile fabric of the presentinvention. As illustrated in FIG. 1, a high pile fabric 5 includes:ground yarns 1 constituting stockinette loops 6; and pile fibers 2 thatare tangled with the loops 6 of the ground yarns 1 and that are openedon a front surface side 7 of a ground structure (high pile fabric 5),thereby forming raised piles 3. Further, at least parts of the pilefibers 2 located on the back surface side 8 of the ground structure(high pile fabric 5) outside of the ground yarns 1 are bonded to theground yarns 1 by heat sensitive sealing, thereby forming a heatsensitive sealing part 4. An organically-modified silicone-basedsoftener that is adhered to the back surface of the pile fabric is notillustrated. FIG. 1 substantially illustrates a schematic positionalrelationship in which the pile fibers 2 are placed under the groundyarns 1. The “outside of the ground yarns 1” in this drawing issubstantially the portion under the ground yarns 1.

Hereinafter, a method for producing the pile fabric according to one ormore embodiments of the present invention will be described.

First, pile fibers including at least one selected from the groupconsisting of acrylic fibers and modacrylic fibers and ground yarnshaving a higher softening point than the pile fibers are used toproduce, in an ordinary method, a pile fabric that includes: a groundstructure; and pile fibers that are tangled with ground yarnsconstituting the ground structure and that stand on a front surface sideof the ground structure. The pile fibers may be composed of acrylicfibers and/or modacrylic fibers. In this step, if pile fibers to whichan organically-modified silicone-based softener is adhered are used asthe pile fibers, it is possible to omit a step of adhering theorganically-modified silicone-based softener such as an amino-modifiedsilicone-based softener to the back surface of the pile fabric(described later), or it is possible to further apply anorganically-modified silicone-based softener. A method for adhering theorganically-modified silicone-based softener such as an amino-modifiedsilicone-based softener to the pile fibers is not particularly limited,and any known method can be adopted appropriately. For example, the pilefibers may be impregnated with or sprayed with the organically-modifiedsilicone-based softener. For simplifying the step, the adhesion of theorganically-modified silicone-based softener to the pile fibers can beperformed simultaneously with dyeing. Of course, the adhesion can beperformed as a separate step from dyeing. In this case, the dyeing stepmay be performed first and then the organically-modified silicone-basedsoftener may be adhered to the pile fibers, from the viewpoint ofimproving the softness of the pile fabric. The organically-modifiedsilicone-based softener may be used alone or in a combination of two ormore kinds. As a material of the pile fabric, marketed fibers to whichan organically-modified silicone-based softener (e.g., amino-modifiedsilicone-based softener) is adhered may be used. In the case of usingsuch marketed fibers to which an organically-modified silicone-basedsoftener is adhered as the pile fibers, an organically-modifiedsilicone-based softener may be adhered further to the fibers beforeproduction of the pile fabric.

Next, the above organically-modified silicone-based softener such as anamino-modified silicone-based softener is adhered to the back surface ofthe pile fabric. Thereby, the organically-modified silicone-basedsoftener is adhered to the pile fibers on the back surface side of thepile fabric. A method for adhering the organically-modifiedsilicone-based softener such as an amino-modified silicone-basedsoftener to the back surface of the pile fabric is not particularlylimited, and any known method can be adopted appropriately. For example,the back surface of the pile fabric may be impregnated with or sprayedwith the organically-modified silicone-based softener. Theorganically-modified silicone-based softener may be used alone or in acombination of two or more kinds.

Softeners generally impart softness and smoothness to fiber surfaces. Inthe present disclosure, surprisingly, in the pile fabric that include aspile fibers at least one selected from the group consisting of acrylicfibers and modacrylic fibers, wherein at least parts of the pile fibersamong the pile fibers located on the back surface side of the pilefabric outside of the ground yarns are fused, it is possible to improvethe softness of the pile fabric while preventing the pile fiber loss byadhering 0.4 parts by weight or more of the above organically-modifiedsilicone-based softener with respect to 100 parts by weight of the pilefibers on the back surface side of the pile fabric. The reason for thisis uncertain, but the following are considered. By adhering theorganically-modified silicone-based softener to the pile fibers on theback surface side of the pile fabric and subjecting the back surfaceside of the pile fabric to heat sensitive sealing at a temperature equalto or higher than the softening point of the pile fibers and lower thanthe softening point of the fibers constituting the ground structure(described later), functional groups such as terminal amino groups inthe organically-modified silicone-based softener, which is adhered tothe pile fibers on the back surface side of the pile fabric, arecross-linked. After production of the pile fabric using pile fibers towhich an organically-modified silicone-based softener is not adhered orpile fibers to which an organically-modified silicone-based softener isadhered, an organically-modified silicone-based softener may be adheredto the back surface side of the pile fabric from the viewpoint ofpreventing the pile fiber loss while improving the softness of the pilefabric more effectively.

Next, the back surface side of the pile fabric is subjected to heatsensitive sealing at a temperature equal to or higher than the softeningpoint of the pile fibers and lower than the softening point of thefibers constituting the ground structure. Thereby, the pile fibersstanding on the front surface side of the ground structure are notfused, whereas part or all of the pile fibers located on the backsurface side of the ground structure outside of the ground yarnsconstituting the ground structure are fused. The heat sensitive sealingcan be performed, e.g., by arranging the back surface side of the pilefabric so as to come into contact with a heating roller or hot plate andapplying pressure by a rubber roller. By using the heating roller or hotplate, the heat sensitive sealing can be performed in a short time, andat least parts of the pile fibers located on the back surface side ofthe ground structure outside of the ground yarns can be bonded by heatsensitive sealing. Further, since the pile fabric is not heated to theextent that the pile fibers on the front surface side of the pile fabricmelt, the pile fibers standing on the front surface side of the groundstructure do not melt.

During and/or after heat sensitive sealing from the back surface side ofthe pile fabric, a side of the pile fabric on which the pile fibersstand may be cooled. Moreover, after heat sensitive sealing from theback surface side of the pile fabric, the back surface side of the pilefabric may be cooled. As the cooling means, the front surface and/or theback surface of the pile fabric may be cooled with a cooling roller inwhich water of 50° C. or lower flows. The temperature of the waterflowing inside the cooling roller may be 10 to 40° C., 10 to 35° C., or15 to 30° C., from the viewpoint of the cooling efficiency andproductivity. Such cooling can maintain the dimensional stability of thepile fabric and reduce heat damage to the pile fibers.

The heat sensitive sealing in the production method of the pile fabricaccording to one or more embodiments of the present invention will bedescribed more specifically with reference to the drawing.

FIG. 2 illustrates a production process schematically showing a heatsensitive sealing step of a pile fabric performed at a predeterminedtemperature from the back surface side of the pile fabric. The heatsensitive sealing, specifically, a processing device 10 to be used inthe heat sensitive sealing, includes a heating roller 11 that is coatedwith a fluorocarbon resin such as polytetrafluoroethylene, a coolingrubber roller 12 in which cooling water of 30° C. flows and that appliespressure to the heating roller 11, a metal cooling roller 13 in whichcooling water of 30° C. flows and that applies pressure to the coolingrubber roller 12, a metal cooling roller 14 in which cooling water of30° C. flows, and a guide roller 15. A raw pile fabric (a high pilefabric to which an organically-modified silicone-based softener isadhered) 18 is led out from a container 16 and supplied so that a backsurface 18 b of the fabric 18 comes into contact with the heating roller11 and a front surface (piloerection side) 18 a thereof comes intocontact with the cooling rubber roller 12. After the heat sensitivesealing, the back surface 18 b is cooled with the metal cooling roller14. A pile fabric 19 after this processing is contained in a container17. Note that the device for the heat sensitive sealing is not limitedto the processing device shown in FIG. 2, and may be a device partiallymodified from the processing device shown in FIG. 2, a hot plate, orother devices. For example, a rubber roller not for cooling may be usedinstead of the cooling rubber roller 12. The metal cooling roller 13 maybe omitted. In the heat sensitive sealing, the heating temperature isnot particularly limited as long as it is equal to or higher than thesoftening point of the pile fibers and lower than the softening point ofthe fibers constituting the ground yarns. The pressure force may be 0.01to 100 Kgf/cm² (0.98 kPa to 9.8 MPa) in linear pressure. The supply rateof the raw pile fabric may be 0.1 to 20 m/minute. The contact time withheater (e.g., heating roller) may be 1 to 60 seconds. The pressure forcemay also be 2.0 to 50 Kgf/cm² (0.20 to 4.9 MPa) in linear pressure, andthe contact time with the heater may also be 1 to 10 seconds, from theviewpoint of reducing damages on the front surface of the pile fabric.

In the case of the high pile fabric, the high pile fabric shrinks in awale direction during the heat sensitive sealing. Therefore, the highpile fabric may be drawn in the wale direction after the heat sensitivesealing.

As the drawing, the high pile fabric is drawn in the wale direction byholding both ends (selvages) of the high pile fabric in the waledirection so that the draw ratio in the wale direction (length) may beabout 5 to 20%, about 7 to 15%, or about 8 to 12%. The draw ratio in thewale direction (length) is expressed by the formula below.

Draw ratio in the wale direction(length)(%)={(Length in the waledirection after drawing−Length in the wale direction beforedrawing)/Length in the wale direction before drawing}×100

When heat is applied during the drawing, the temperature of the drawingmay be 90 to 150° C., 100 to 130° C., or 105 to 120° C.

Such drawing can be performed using known devices such as a tenter. Thetenter, generally used for heat setting, heats fabrics at apredetermined temperature while holding both selvages of the fabrics towiden the fabrics to a predetermined width. However, the above heatingis not essential in one or more embodiments of the present invention.Exemplary methods for holding the selvages of fabrics in the tentorinclude a clip tentor method and a pin tentor method, and both of themcan be used. The pin tentor method may be used from the viewpoint ofstep stability and/or productivity.

In the case of performing the drawing while heating the high pilefabric, a minimum temperature and a minimum volume of air necessary forthe drawing may be set to prevent the surfaces of the high pile fabricfrom being damaged.

The pile fabric according to one or more embodiments of the presentinvention can prevent the fiber loss. The average amount of the fiberloss measured in accordance with the method below may be 4.0 g/m² orless, 3.0 g/m² or less, or 2.0 g/m² or less. The maximum amount of thefiber loss measured in accordance with the method below may be 5.0 g/m²or less, 4.0 g/m² or less, or 3.0 g/m² or less.

In one or more embodiments of the present invention, a distance at 90°of the pile fabric measured in accordance with the method below may be50 mm or less, or 45 mm or less, from the viewpoint of excellentsoftness.

EXAMPLES

Hereinafter, one or more embodiments of the present invention will bedescribed more specifically by way of examples. Note that the presentinvention is not limited to the examples below.

<Measurement Method>

1. Amount of Fiber Loss

As illustrated in FIG. 3, a pile fabric 21 (length: 280 mm, width: 210mm) was placed on an inclined surface of a metal plate 22 so that thepile direction of the fabric would be oriented toward the upper side ofthe inclined surface. The metal plate 22 arranged obliquely had aninclination angle a of 30°. An adhesive tape 23 (Scotch No. 850manufactured by 3M company, width: 25 mm) cut in a length of 100 mm wasstuck on the surface of the pile fabric 21, to which a load of 1.5 g/cm²was applied for one minute from the top of the adhesive tape 23 (notillustrated). Then, the adhesive tape 23 was continuously peeled offfrom the pile fabric 21 from an end of the tape 23 located at the upperpart of the inclined surface. The weight (g) of the fibers attached tothe adhesive tape was measured, and the weight of the fibers per area ofthe adhesive tape (g/m²) was calculated to determine the amount of thefiber loss. The amounts of the fiber loss at any of three sections inthe pile fabric were measured and calculated as described above todetermine the average amount of the fiber loss and the maximum amount ofthe fiber loss.

2. Evaluation of Fiber Loss

The fiber loss of the pile fabric was ranked into the following fourgrades based on the amount of the fiber loss. The evaluations of S, A,and B mean pass, and the evaluation of C means fail.

S: The average amount of the fiber loss is 2.0 g/m² or less, and themaximum amount of the fiber loss is 3.0 g/m² or less.A: The average amount of the fiber loss is more than 2.0 g/m² and 3.0g/m² or less, and the maximum amount of the fiber loss is more than 3.0g/m² and 4.0 g/m² or less.B: The average amount of the fiber loss is more than 3.0 g/m² and 4.0g/m² or less, and the maximum amount of the fiber loss is more than 4.0g/m² and 5.0 g/m² or less.C: The average amount of the fiber loss is more than 4.0 g/m², and themaximum amount of the fiber loss is more than 5.0 g/m² (failure level)

(Softness of Pile Fabric)

(1) The pile fabric was cut in the warp direction into a width of 20 mmto obtain a cloth piece having a length of 200 mm and a width of 20 mm.

(2) As illustrate in FIG. 4A, the cloth piece 31 of the pile fabric wasarranged on a horizontal board 32 (width: 600 mm, length: 600 mm) madefrom melamine resin. Next, the cloth piece 31 of the pile fabric wasgradually slid out of the horizontal board 32 along the pile directionof the pile fabric.

(3) As illustrated in FIG. 4B, the cloth piece 31 of the pile fabric wasslid until a tangent 41 and the horizontal board 32 formed an angle a of90°. The tangent 41 was drawn to the tip of the cloth piece 31 of thepile fabric extending out of the horizontal board 32.

(4) A distance L (distance at 90°) of the cloth piece 31 of the pilefabric sliding out from the horizontal board 32 was measured to evaluatethe softness of the pile fabric in accordance with the followingcriteria.

A: The distance at 90° is less than 50 mm (the pile fabric is verysoft).B: The distance at 90° is 50 mm or more and 55 mm or less (the pilefabric is soft).C: The distance at 90° exceeds 55 mm (the pile fabric is hard).

<Fibers>

1. Pile Fibers

(1) Trade name “Kanekalon (registered trademark) ELP” (manufactured byKaneka Corporation): modacrylic fiber (vinyl chloride-acrylonitrilefiber), softening point: 180 to 190° C., fineness: 27 dtex, cut length:102 mm (hereinafter, referred to as ELP simply), with no adhesion of anamino-modified silicone-based softener

(2) Trade name “Kanekalon (registered trademark) AH” (manufactured byKaneka Corporation): modacrylic fiber (vinyl chloride-acrylonitrilefiber), softening point: 180 to 190° C., fineness: 7.8 dtex, cut length:76 mm (hereinafter, referred to as AH7.8 simply), with adhesion of 0.3parts by weight of an amino-modified silicone-based softener to 100parts by weight of fibers (analysis value calculated from X-rayfluorescence analysis)

(3) Trade name “Kanekalon (registered trademark) AH” (manufactured byKaneka Corporation): modacrylic fiber (vinyl chloride-acrylonitrilefiber), softening point: 180 to 190° C., fineness: 5.6 dtex, cut length:51 mm (hereinafter, referred to as AH5.6 simply), with adhesion of 0.3parts by weight of an amino-modified silicone-based softener to 100parts by weight of fibers (analysis value calculated from X-rayfluorescence analysis)

(4) Trade name “Kanekalon (registered trademark) MCS” (manufactured byKaneka Corporation): modacrylic fiber (vinyl chloride-acrylonitrilefiber), softening point: 180 to 190° C., fineness: 4.4 dtex, cut length:32 mm (hereinafter, referred to as MCS simply), with no adhesion of anamino-modified silicone-based softener

In the above, the adhesion amount of the amino-modified silicone-basedsoftener in the modacrylic fibers was determined by quantifying the Sielement in accordance with X-ray fluorescence analysis using awavelength dispersion type X-ray fluorescence analyzer, and creating thecalibration curve. Specifically, with use of an X-ray fluorescencespectrometer RIX 3100 (manufactured by Rigaku Corporation), the Sielement was analyzed under the following conditions: Rh tube (tubecurrent: 50 mA−tube voltage: 50 kV), measurement diameter: 30 mmϕ,analyzing crystal:pentaerythritol (PET), and 2θ angle: 106 to 112°, andfirst, a calibration curve was created using a sample whoseamino-modified silicone-based softener content was known. Next, the Sielement of a measurement sample (thickness: 3 mm, diameter: 30 mm) wasanalyzed which was obtained by molding fibers to be measured withpressure using a press (tablet molding machine). The adhesion amount ofthe amino-modified silicone-based softener was calculated bysubstituting the obtained Si detection count into a calibration curveequation.

2. Ground Structure Constituent Fibers (Ground Yarns)

A multifilament with a total fineness of 334 dtex (a fiber yarn composedof two filaments, each filament having a fineness of 167 dtex andcomposed of 50 polyester single fibers) was used. The softening pointwas 258° C.

The softening point of the fibers is a temperature determined in thefollowing manner. 1 g of fibers is opened, placed on a hot plate heatedto a predetermined temperature, and pressurized with a pressure rollerat 0.07 Kgf/cm² (nip pressure) for 3 seconds. The temperature at whichthe surfaces of single fibers in contact with the hot plate are softenand bonded to each other into a plate shape is defined as the softeningpoint of the fibers.

Example 1

With use of a sliver knitting machine (circular knitting machine) forproduction of fake furs and the above polyester fiber yarns as theground yarns, a high pile fabric of Example 1 was knitted by supplying apile fiber sliver (10 to 14 g) composed of ELP, AH7.8 and AH5.6 mixeduniformly in a ratio of ELP/AH7.8/AH5.6=15/35/50 (wt %). The number ofloops in the wale of the ground structure was 16 to 17/inch, and thenumber of loops in the course of the ground structure was 22 to 33/inch.Next, the pile fibers on the piloerection surface side of the high pilefabric were aligned by polishing and shearing. Specifically, first, thepile fibers were polished twice at 120° C., and then sheared twice.

An aqueous solution of an amino-modified silicone-based softener (tradename “Matsumoto Silicone Softener N-20” manufactured by MatsumotoYushi-Seiyaku Co., Ltd., solid content: 20 wt %) was sprayed on the backsurface of the obtained high pile fabric so that 0.2 parts by weight ofthe amino-modified silicone-based softener (solid content) would beadhered to 100 parts by weight of the pile fibers on the back surfaceside. Thereafter, the high pile fabric was dried for 3 minutes using apin tentor drier at an inner drier temperature of 125° C. while drawingthe width to 160 cm, followed by cooling to 80° C. or lower with thewidth being held at 160 cm.

The heat sensitive sealing was performed with respect to the backsurface of the high pile fabric (width: 160 cm) with a heat sensitivesealing device shown in FIG. 2 under the following conditions: thetemperature of the heating roller: 215° C., the contact time between theheating roller and the high pile fabric: 3 seconds, the nip pressure ofthe heating roller and the cooling rubber roller: 50 Kgf/cm² (4.9 MPa).At this time, the width of the high pile fabric shrank to 135 cm.Thereafter, the high pile fabric was dried for 3 minutes using a pintentor drier at an inner drier temperature of 125° C. while drawing thewidth to 160 cm, followed by cooling to 80° C. or lower with the widthbeing held at 160 cm.

In the high pile fabric obtained, the pile fibers on the front surfaceside of the pile fabric were aligned by polishing, brushing, andshearing. Specifically, first, the pile fibers were brushed twice,polished once at each of 155° C., 150° C., 145° C., 130° C. and 120° C.,then sheared twice, and lastly polished twice at 100° C. Consequently, ahigh pile fabric with a weight per unit area of 700 g/m² and a pilefiber length at piloerection portion of 20 mm was obtained.

Example 2

A high pile fabric of Example 2 was produced in the same manner as inExample 1 except that the aqueous solution of the amino-modifiedsilicone-based softener was sprayed on the back surface of the high pilefabric so that 1 part by weight of the amino-modified silicone-basedsoftener (solid content) would be adhered to 100 parts by weight of thepile fibers on the back surface side of the pile fabric.

Comparative Example 1

A high pile fabric of Comparative Example 1 was produced in the samemanner as in Example 1 except that an unmodified silicone-based softener(trade name “Dimethyl Silicone K” manufactured by MatsumotoYushi-Seiyaku Co., Ltd., the solid content: 20 wt %) was used in placeof the amino-modified silicone-based softener.

Comparative Example 2

A high pile fabric of Comparative Example 2 was produced in the samemanner as in Example 2 except that an unmodified silicone-based softener(trade name “Dimethyl Silicone K” manufactured by MatsumotoYushi-Seiyaku Co., Ltd., the solid content: 20 wt %) was used in placeof the amino-modified silicone-based softener.

Comparative Example 3

A high pile fabric of Comparative Example 3 was produced in the samemanner as in Example 1 except that a fatty acid-based softener (“PK-608”manufactured by Yancheng Jiaye Textile Materials Co., Ltd., the solidcontent: 20 wt %) was used in place of the amino-modified silicone-basedsoftener.

Comparative Example 4

A high pile fabric of Comparative Example 4 was produced in the samemanner as in Example 2 except that a fatty acid-based softener (“PK-608”manufactured by Yancheng Jiaye Textile Materials Co., Ltd., the solidcontent: 20 wt %) was used in place of the amino-modified silicone-basedsoftener.

Comparative Example 5

A high pile fabric of Comparative Example 5 was produced in the samemanner as in Example 1 except that the heat sensitive sealing wasperformed without adhering a softener to the pile fibers on the backsurface side of the pile fabric.

Comparative Example 6

A high pile fabric of Comparative Example 6 was produced in the samemanner as in Example 1 except that a sliver (10 to 14 g) composed of 100wt % of AH7.8 was used as the pile fiber sliver.

Comparative Example 7

A high pile fabric of Comparative Example 7 was produced in the samemanner as in Example 1 except that a sliver (10 to 14 g) composed of ELPand MCS mixed uniformly in a ratio of ELP/MCS=20/80 (wt %) was used asthe pile fiber sliver.

The fiber loss and the softness of the high pile fabrics obtained inExamples 1 to 2 and Comparative Examples 1 to 7 were measured andevaluated by the methods described above. Table 1 below shows theresults. In Table 1, Adhesion amount of softener is a weight ratio ofthe softener with respect to 100 parts by weight of the pile fibers onthe back surface side of the pile fabric. Specifically, in Example 1,the adhesion amount of the softener is the sum of the amount of thesoftener adhered to the fibers used as the material of the pile fibersand the amount of the softener of the same kind additionally adhered tothe pile fibers on the back surface side of the pile fabric in theproduction step of the pile fabric, and calculated in the followingmanner. In Example 2 and Comparative Examples 1 to 7, the adhesionamounts of the respective softeners were calculated in the same manneras in Example 1.

Example 1: The amount of the amino-modified silicone-based softeneradhered with respect to 100 parts by weight of the fibers used as thematerial of the pile fibers=AH7.8 and AH5.6 derivatives=3 (parts byweight)×85 (wt %)=0.255 parts by weightThe amount of the amino-modified silicone-based softener additionallyadhered with respect to 100 parts by weight of the pile fibers on theback surface side of the pile fabric in the production step of the pilefabric=0.2 parts by weightThe adhesion amount of the amino-modified silicone-based softener to 100parts by weight of the pile fibers on the back surface side of the pilefabric=0.255+0.2 (parts by weight)=0.455 parts by weight

TABLE 1 Adhesion amount of softener (parts by weight) Amino- modifiedUnmodified Fiber loss Softness silicone- silicone- Fatty Amount of fiberloss Distance at based based acid-based Average Maximum 90° softenersoftener softener (g/m²) (g/m²) Evaluation (mm) Evaluation Ex. 1 0.455 // 1.49 1.81 S 44 A Ex. 2 1.255 / / 2.28 2.92 A 40 A Comp. Ex. 1 0.2550.2 / 4.24 5.74 C 39 A Comp. Ex. 2 0.255 1   / 4.72 5.36 C 37 A Comp.Ex. 3 0.255 / 0.2 4.33 5.55 C 41 A Comp. Ex. 4 0.255 / 1   4.85 5.61 C41 A Comp. Ex. 5 0.255 / / 2.29 2.55 A 56 C Comp. Ex. 6 0.3 / / 3.123.35 B 63 C Comp. Ex. 7 / / / 2.37 2.89 A 61 C *Example: Ex. ComparativeExample: Comp. Ex.

As can be seen from the results of Table 1 above, the pile fabrics ofExamples 1 and 2, in which 0.4 parts by weight or more of theamino-modified silicone-based softener was adhered with respect to 100parts by weight of the pile fibers on the back surface side of the pilefabric, resulted in high softness and reduced pile fiber loss.

Meanwhile, the pile fabrics of Comparative Examples 1 and 2, in whichthe total adhesion amount of the amino-modified silicone-based softenerand the unmodified silicone-based softener to the pile fibers on theback surface side of the pile fabrics was 0.4 parts by weight or morewith respect to 100 parts by weight of the pile fibers on the backsurface side but the adhesion amount of the amino-modifiedsilicone-based softener with respect to 100 parts by weight of the pilefibers on the back surface side was less than 0.4 parts by weight,resulted in favorable softness but a large amount of pile fiber loss.Moreover, the pile fabrics of Comparative Examples 3 and 4, in which thetotal adhesion amount of the amino-modified silicone-based softener andthe fatty acid-based softener to the pile fibers on the back surfaceside of the pile fabrics was 0.4 parts by weight or more with respect to100 parts by weight of the pile fibers on the back surface side but theadhesion amount of the amino-modified silicone-based softener withrespect to 100 parts by weight of the pile fibers on the back surfaceside was less than 0.4 parts by weight, resulted in favorable softnessbut a large amount of pile fiber loss. Moreover, the pile fabrics ofComparative Examples 5 and 6, in which the adhesion amount of theamino-modified silicone-based softener to the pile fibers on the backsurface side of the pile fabrics was less than 0.4 parts by weight withrespect to 100 parts by weight of the pile fibers on the back surfaceside, and the pile fabric of Comparative Example 7, in which theamino-modified silicone-based softener was not adhered to the pilefibers on the back surface side of the pile fabric, resulted in reducedpile fiber loss but hard texture.

Although the disclosure has been described with respect to only alimited number of embodiments, those skilled in the art, having benefitof this disclosure, will appreciate that various other embodiments maybe devised without departing from the scope of the present invention.Accordingly, the scope of the invention should be limited only by theattached claims.

DESCRIPTION OF REFERENCE NUMERALS

-   -   1 ground yarn    -   2 pile fiber    -   3 raised pile    -   4 heat sensitive sealing part    -   5 high pile fabric    -   6 loop    -   7 front surface side    -   8 back surface side    -   10 processing device    -   11 heating roller    -   12 cooling rubber roller    -   13,14 metal cooling roller    -   15 guide roller    -   16,17 container    -   18 raw pile fabric    -   18 a front surface side of raw pile fabric    -   18 b back surface side of raw pile fabric    -   19, 21 pile fabric    -   22 metal plate    -   23 adhesive tape    -   31 cloth piece of pile fabric    -   32 horizontal board    -   41 tangent drawn to the tip of the cloth piece of pile fabric

What is claimed is:
 1. A pile fabric, comprising: ground yarnsconstituting a ground structure; pile fibers that are tangled with theground yarns, the pile fibers comprising portions standing on a frontsurface side of the ground structure; and an organically-modifiedsilicone-based softener adhered to the pile fibers located on a backsurface side of the pile fabric, wherein the pile fibers comprise atleast one selected from the group consisting of acrylic fibers andmodacrylic fibers, and have a softening point lower than a softeningpoint of the ground yarns, wherein the portions standing on the frontsurface side of the ground structure are not fused to each other, and ona back surface side of the ground structure, at least part of the pilefibers located outside of the ground yarns are fused to each other,wherein an amount of the organically-modified silicone-based softener is0.4 parts by weight or more with respect to 100 parts by weight of thepile fibers located on the back surface side of the pile fabric, andwherein the organically-modified silicone-based softener is at least oneselected from the group consisting of amino-modified silicone-basedsofteners, epoxy-modified silicone-based softeners, andcarboxyl-modified silicone-based softeners.
 2. The pile fabric accordingto claim 1, wherein the organically-modified silicone-based softener isan amino-modified silicone-based softener.
 3. The pile fabric accordingto claim 1, wherein the pile fibers are modacrylic fibers.
 4. The pilefabric according to claim 2, wherein the pile fibers are modacrylicfibers.
 5. The pile fabric according to claim 1, wherein the groundyarns are polyester fiber yarns.
 6. The pile fabric according to claim2, wherein the ground yarns are polyester fiber yarns.
 7. The pilefabric according to claim 3, wherein the ground yarns are polyesterfiber yarns.
 8. The pile fabric according to claim 1, wherein the amountof the organically-modified silicone-based softener is 0.4 to 2.5 partsby weight with respect to 100 parts by weight of the pile fibers locatedon the back surface side of the pile fabric.
 9. The pile fabricaccording to claim 2, wherein the amount of the organically-modifiedsilicone-based softener is 0.4 to 2.5 parts by weight with respect to100 parts by weight of the pile fibers located on the back surface sideof the pile fabric.
 10. The pile fabric according to claim 3, whereinthe amount of the organically-modified silicone-based softener is 0.4 to2.5 parts by weight with respect to 100 parts by weight of the pilefibers located on the back surface side of the pile fabric.
 11. A methodfor producing a pile fabric, comprising: preparing a pile fabric,wherein the pile fabric comprises ground yarns constituting a groundstructure and pile fibers that are tangled with the ground yarns, thepile fibers comprising portions standing on a front surface side of theground structure; attaching an organically-modified silicone-basedsoftener to the pile fibers located on a back surface side of the pilefabric; and heat sealing the back surface side of the pile fabric at atemperature that is equal to or higher than a softening point of thepile fibers and lower than a softening point of the ground yarns,wherein the pile fibers comprise at least one selected from the groupconsisting of acrylic fibers and modacrylic fibers, and have a softeningpoint lower than a softening point of the ground yarns, wherein anamount of the organically-modified silicone-based softener is 0.4 partsby weight or more with respect to 100 parts by weight of the pile fiberslocated on the back surface side of the pile fabric, wherein theorganically-modified silicone-based softener is at least one selectedfrom the group consisting of amino-modified silicone-based softeners,epoxy-modified silicone-based softeners, and carboxyl-modifiedsilicone-based softeners, and wherein the portions of the pile fibersstanding on the front surface side of the ground structure are not fusedto each other, and on a back surface side of the ground structure, atleast part of the pile fibers located outside of the ground yarns arefused to each other after the heat sealing.
 12. The method for producinga pile fabric according to claim 11, wherein the organically-modifiedsilicone-based softener is an amino-modified silicone-based softener.13. The method for producing a pile fabric according to claim 11,wherein the pile fibers are modacrylic fibers.
 14. The method forproducing a pile fabric according to claim 12, wherein the pile fibersare modacrylic fibers.
 15. The method for producing a pile fabricaccording to claim 11, wherein the ground yarns are polyester fiberyarns.
 16. The method for producing a pile fabric according to claim 12,wherein the ground yarns are polyester fiber yarns.
 17. The method forproducing a pile fabric according to claim 13, wherein the ground yarnsare polyester fiber yarns.
 18. The method for producing a pile fabricaccording to claim 11, wherein the amount of the organically-modifiedsilicone-based softener is 0.4 to 2.5 parts by weight with respect to100 parts by weight of the pile fibers located on the back surface sideof the pile fabric.
 19. The method for producing a pile fabric accordingto claim 12, wherein the amount of the organically-modifiedsilicone-based softener is 0.4 to 2.5 parts by weight with respect to100 parts by weight of the pile fibers located on the back surface sideof the pile fabric.
 20. The method for producing a pile fabric accordingto claim 13, wherein the amount of the organically-modifiedsilicone-based softener is 0.4 to 2.5 parts by weight with respect to100 parts by weight of the pile fibers located on the back surface sideof the pile fabric.